Safety needle device with snap feature and method of making same

ABSTRACT

The present invention safety device is a one-piece needle assembly that has a base and a housing pivotally connected to the base. The base has a distal portion to which a needle is fitted. At the base there is formed longitudinally along its distal portion a catch mechanism that may be in the form of an anchor projection. At the back wall of the housing there is extended another catch mechanism that may be configured in the form of two clasping fingers. Also providing in the housing is an integral hook. As the housing and the base are pivoted relative to each other, and as the needle makes contact with the hook, the respective catch mechanisms at the base and the housing also make contact with each other, resulting in the coupling of the catch mechanisms and the coupling of the needle to the hook. As a result, the catch mechanisms are interlocked and the needle is fixedly retained by the hook within the housing. The catch mechanisms may also be configured as a hook and a latch in the form of a rib with an opening whereto the hook is fixedly coupled. The catch mechanisms may further be configured as respective interlockable pairs of loops and bosses. The gauge of the needle may be determined by the color of both the base and the housing, which are molded as a unitary single unit.

RELATED APPLICATION

The present application is related to application Ser. No. 11/029,391 filed on Jan. 6, 2005.

FIELD OF THE INVENTION

The present invention relates to needle protection devices and more particularly to a needle assembly, adaptable to be used with a syringe, that includes mechanisms at its base and housing that coact to non-removably retain the housing and the base in a secured relationship, at the same time that the needle of the assembly is being fixedly secured by a hook mechanism in the housing.

BACKGROUND OF THE INVENTION

Needle protection devices that utilize a housing that pivots relative to the base are exemplified by a number of U.S. patents assigned to the assignee of the instant application. These include U.S. Pat. Nos. 4,982,842, 5,139,489, 5,154,285, 5,232,454, 5,232,455, 5,277,311 and 5,423,765, among others. There are other patents also assigned to the assignee of the instant invention that disclose the anchoring of the housing to the base of a needle. In U.S. patents RE37,110, RE37,252 and U.S. Pat. No. 6,328,713, there is disclosed the mating of an anchor at the base to an opening at the housing. Although feasible, it has been found that such embodiment entails the need for an anchor that has to be of a given length, as well as an opening that has to be well defined. Moreover, the portion of the housing where the opening is to be provided has to be sufficiently thin so as to provide the flexibility that enables the anchor to first pierce through and then be anchored to the opening. Further, with the anchor piercing through the housing, given that contaminated blood may well be splattered to the anchor as the housing closes over the contaminated needle, there may be a chance that contaminated fluid from the needle may be exposed on the backside of the housing where the anchor protrudes. Furthermore, such anchor based needle protection device is difficult to implement with a hook mechanism inside the housing, as the contact between the anchor and the opening at the housing would conflict with the retention of the needle by a hook in the housing, as exemplified by the aforenoted U.S. Pat. No. 4,982,842.

SUMMARY OF THE INVENTION

The present invention safety needle device has a locking mechanism that has one portion extending from the back wall of the housing and another portion extending from the base in such a way that when the housing is pivoted toward the base to cover the needle that extends from the base, the portions of the catch mechanism would couple together to fixedly retain the housing and the base relative to each other. One portion of the catch mechanism is configured to have two fingers closing in on a slot through which the other portion of the catch mechanism, in the form of an elongated anchor or projection, snaps into and be held by the fingers. The two portions of the catch mechanism are designed such that they would matingly couple at substantially the same time as the needle is clasped and be retained by an integral hook in the housing. This configuration ensures that a single pivoting movement of the housing relative to the base would enable the hook in the housing to fixedly retain the needle and at the same time enable the housing and the base be fixedly retained relative to each other. Two flaps each extending from a side wall of the housing prevent further access to the portions of the catch mechanism once those portions are coupled to each other. Each portion in turn may be considered a catch mechanism so that the safety device of the instant invention may be considered to have two coacting catch mechanisms.

The safety needle device of the instant invention is formed from the same mold such that the housing, the base, the portions of the catch mechanism as well as the hook, are integrally formed as a single unitary unit. The needle is fitted to the distal end of the base while the proximal end of the base is configured to be adaptable to a syringe or other medical apparatus for either withdrawing fluid from or ejecting medication to a patient. The needle that is attached to the base of the safety device of the instant invention may be of different gauges. To signify the gauge of the needle, the housing and the base of the safety device are color coded to a given color that has been predetermined to correspond to that given needle gauge.

The instant invention is therefore a needle assembly that has a base having a needle extending therefrom along a longitudinal axis thereof, a housing pivotally connected to the base with two side walls connected by a back wall, one portion of a catch or lock mechanism extends from the back wall so as to couple to another portion of the catch mechanism that extends from the base, so that once the portions of the catch mechanism are coupled to each other, the housing and the base are fixedly retained relative to each other, with the needle being covered by the housing.

The instant invention also relates to a one-piece needle assembly or safety device that is adaptable to be used with a syringe, with the respective portions of the catch mechanism being provided at the base and the housing per discussed above.

The instant invention further relates to a one-piece needle assembly or safety device that has a base having a needle extending therefrom along a longitudinal axis, a housing pivotally connected to the base and having two side walls connected by a back wall, a pair of adjacent first catches that extend from the back wall, a rib extending from the base orthogonal to the longitudinal axis and a pair of second catches that protrude from the rib, so that when the housing is pivoted towards the base to cover the needle, each of the first catches would mate with a corresponding one of the second catches to fixedly retain the housing and the base relative to each other. One pair of the pairs of first and second catches may be loops while the other pair may be bosses or fingers that the loops would snap over when the housing pivots towards and covers the needle.

The instant invention also relates to a method of manufacturing a safety device or a needle assembly that is matable with a syringe, with the safety device having a housing and a base pivotally connected to each other. The housing has a back wall and two sidewalls together that form a slot through which the needle of the needle assembly passes when the housing is pivoted towards the base to cover the needle. The method comprises the steps of extending one catch mechanism from the back wall of the housing and providing another catch mechanism at a location at the base that would ensure that the one and other catch mechanisms are non-removably interlocked to each other when the housing is pivoted to cover the needle. The method of the instant invention also provides for the extending of a rib from the base in a direction facing the housing and the providing of a boss at each side of the rib, and a pair of loops provided as the catch mechanism that extends from the back wall of the housing.

BRIEF DESCRIPTION OF THE FIGURES

The present invention will become apparent and the invention itself will be best understood with reference to the following description of the present invention taken in conjunction with the accompanying drawings, wherein:

FIG. 1 is a perspective view of the safety device of the instant invention in a free standing position, with the housing being cross-sectioned;

FIG. 2 is a view of the safety device of the instant invention, with the housing being shown in cross-section, as the housing and the base of the device are moved relatively towards each other;

FIG. 3 shows the device in a fully actuated position with the locking snaps of the catch mechanism engaged.

FIG. 4 is another perspective view of the device of the instant invention;

FIG. 5 is a top view of the safety device of FIG. 4;

FIG. 6 is a side view of the safety device of FIG. 4;

FIG. 7 shows the view at cross-section A-A of FIG. 5;

FIG. 8 is an enlarged view of detail A as shown in FIG. 5;

FIG. 9 is a perspective view of the instant invention safety device that has an alternative catch mechanism at the base of the device;

FIG. 10 is an enlarged detail of the alternative catch mechanism;

FIG. 11 is another embodiment of the instant invention safety device in which alternative catch mechanisms are provided at the base and the housing of the device;

FIG. 12 illustrates the safety device of FIG. 11 in which the housing has been coupled to the base, with the catch mechanisms interlocked;

FIG. 13 is a perspective view of the device of FIG. 11;

FIG. 14 is a plan view of the FIG. 13 safety device;

FIG. 15 is a side view of the FIG. 13 safety device;

FIG. 16 is an enlarged detail of the catch mechanism at the base of the safety device of FIG. 13;

FIG. 17 is an enlarged detail of the other catch mechanism of the safety device of FIG. 13;

FIG. 18 is a sectional view of the catch mechanism at the housing of the safety device of FIG. 13;

FIG. 19 is a cross-sectional view showing the interlocking of the catch mechanisms of the safety device of FIG. 13;

FIG. 20 is a perspective view of a syringe having connected thereto another embodiment of the needle assembly of the instant invention;

FIG. 21 is a partially cut-away perspective view the embodiment of the needle assembly of FIG. 20; and

FIG. 22 is a partial sectional view of the needle assembly of FIG. 21 showing a catch mechanism extending from the back wall of the housing mated to a catch mechanism provided at the rib of the base that faces the housing.

DETAILED DESCRIPTION OF THE INVENTION

With reference to the figures, the safety device of the instant invention is a needle assembly that has a base 2 and a housing 4 pivotally connected to the base by a living hinge 6. A needle 8 is adaptable to be fitted to the distal portion 10 of base 2. Needle 8 may be molded to the distal end 12 of base 2, or may be fitted thereto after the safety device has been removed from the mold. The proximal portion 14 of base 2 is configured to have a cavity that is adaptable to mate with a syringe, or other fluid storing devices, not shown. A luer connector 16 is provided at base 2.

There are a number of extensions, or ribs, 18 a-18 c provided at the distal portion 10 of base 2. There is moreover a catch mechanism 20 that extends from distal portion 10 of base 2 at a location facing housing 4. Catch mechanism 20 may be considered as one portion of an overall catch or locking mechanism, as explained below.

Housing 4 is connected to base 2 via living hinge 6. Housing 4 has two sidewalls 22 connected by a back wall 24. A slot or passage 26 for housing 4 is defined by sidewalls 22. It is through passage 26 that needle 8 passes when housing 4 and base 2 are pivoted relative to each other, as shown in FIG. 2.

Extending from back wall 24 is a second catch or locking mechanism 28 that includes two grasping fingers 30. An opening 32 is configured between the grasping fingers 30. As best shown in FIG. 5 and the cross-sectional view in FIG. 7, each of the fingers 30 is configured to fold inward per its fingertip 34. The space defined by the fingers 30 is dimensioned to accommodate catch mechanism 20 at base 2 of the device, as best shown in FIGS. 5 and the enlarged view thereof in FIG. 8.

Catch mechanism 20 for the embodiment shown in FIG. 8 is in the form of an anchor or a projection that extends longitudinally along the distal portion 10 of base 2. Anchor 20 has a front surface 35 and two arrow shaped extensions 36. As the front surfaces 36A of the extensions 36 are inclined at an angle, when catch mechanism 20 meets with catch mechanism 28, the anchor extensions 36 would readily coact with the slant inward tips of fingers 30 to thereby readily engage with those fingers. The back surfaces 36 b of catch mechanism 20 and the inwards folding finger tips 34 of catch mechanism 30 coact to prevent catch mechanism 20 and catch mechanism 30 from being removed from each other, thereby securely and non-removably coupling housing 4 to base 2. Thus, as best shown in FIGS. 2 and 3, when housing 4 and base 2 are pivoted relative to each other, as catch mechanism 20 at base 2 meets catch mechanism 28 at housing 4, catch mechanism 20 would snap into catch mechanism 30 so that both catch mechanisms interlock with each other, as best shown in FIG. 3. As discussed previously, catch mechanisms 20 and 28 may each be considered a portion of an overall catch or interlocking mechanism of the safety device of the instant invention.

Each of the sidewalls 22 has an extension 38 at its proximal portion. Together the side extensions 38 provide a protective environment for catch mechanism 28 that extends from the back wall 24 of housing 4. When catch mechanism 28 is interlocked with catch mechanism 20 as housing 4 is pivoted toward base 2 and covers needle 8, the side extensions 38 of housing 4 would prevent further access to the interlocked catch mechanisms to thereby impede any attempt to remove housing 4 from base 2.

Also integrated to housing 4 is a hook mechanism 40 that acts to clasp needle 8, when housing 4 is pivoted toward base 4 to cover needle 8. Hook 40 fixedly retains needle 8, once needle 8 snaps past the lip portion of hook 4 and is retained by the backside of the lip of hook 40.

As best shown in FIG. 2, the placement of hook mechanism 40 and catch mechanism 28, as well as the extension of those mechanisms from the back wall 24 of housing 4, are such that when housing 4 and base 2 are relatively pivoted toward each other, both needle 8 and catch mechanism 20 would make contact at substantially the same time with hook mechanism 40 and catch mechanism 28, respectively, so that both needle 8 and base 4 are secured to housing 4 at substantially the same time. By providing a combined interlocking of the needle and the base to the back wall of housing 4, needle 8 is ensured to be securely covered by housing 4 and not be re-exposed to the environment.

By providing catch mechanisms that extend from the back wall of the housing and from the base, and further configuring catch mechanism 20 to extend longitudinally along the distal portion of base 2, the coupling of housing 4 to base 2 is ensured to be more secured, as the coupling of housing 4 and base 2 is effected by the interlocking of the catch mechanisms as well as the clasping of needle 8 by hook 40. Thus, by effecting two catch points from the back wall of the housing, i.e., the interlocking of the catch mechanisms and the clasping of the needle by the hook, the housing is more securely held to the base to thereby ensure that the needle is securely covered. Further, by preventing access to the interlocked catch mechanisms, needle 8 could not be unlatched from hook 40.

Base 2 and housing 4, as well as the catch mechanisms 20 and 28 and hook 40, are formed as an integral unitary unit from the same mold. It may, for example, be injection molded.

Prior to use, needle 8 may be covered by a sheath, not shown, that fits over distal portion 10 of base 2. Further, the safety device of the instant invention may be molded or fitted with a number of different needles each having a different gauge. For the instant invention needle assembly, depending on the gauge of the needle fitted to the base, the safety device may be color coded to a predetermined color so that, without looking at needle 8 which is covered by the sheath, a user can readily ascertain the gauge of the needle. Thus, the molded one-piece unit of the safety device of the instant invention is color coded to have a predetermined color that signifies the gauge of the particular needle that is attached to its base. A more detailed discussion of such color coding of the needle to the body of the device is provided in application No. 10/751,982 having filing date of Jan. 7, 2004. The disclosure of the '982 application is incorporated by reference herein.

An alternative embodiment of the catch mechanism at the base of the safety device is shown in FIGS. 9 and 10. The difference between the device shown in FIG. 9 and that shown in FIGS. 1-8 is the configuration of the anchor or projection 20′. As shown in greater detail in FIG. 10, catch mechanism 20′ has a front surface 20′f that is curved, in contrast to the inclined side surfaces 36 a of catch mechanism 20, as shown in FIG. 8. Furthermore, the back surfaces 20′b of projection 20′ are not inwardly angled. The configuration of the tips of the respective fingers 30 could be adjusted to ensure that those fingertips could fixedly grasp onto the respective back surfaces 20′b, once the head of projection 20′ is moved between the fingers and passed the fingertips. Like the previous embodiment, catch mechanisms 30 and 20′ make contact substantially at the same time as hook 40 makes contact with the needle, not shown, that extends from the distal end 10 of base 2.

The catch mechanisms for the safety device shown in FIGS. 11-15 are different from those shown earlier. Specifically, the catch mechanism extending from the back wall 24 of housing 4 is configured in the form of a hook 42, as best shown by the enlarged detail illustration of FIG. 17. There it can be seen that hook 42 has an extension 42 a and a tip 42 b. Coacting with hook 42, at the distal portion 10 of base 2 of the safety device, is a latch in the form of a rib 44 that extends substantially longitudinally along the length of the distal portion 10 of base 2. An opening 46 is provided in rib 44. It is through opening 46 that the tip 42 b of hook 42 latches onto, when housing 4 and base 2 are moved relatively toward each other. As best shown in the fully actuated position of FIG. 19, when hook 42 is interlocked with rib 44, housing 4 and base 2 of the safety device are fixedly retained relative to each other. FIG. 12 shows the fingertip 42 b of hook 42 extending through opening 46 of rib 44, to thereby firmly latch onto rib 44. FIG. 12 also shows needle 8 being grasped by hook 40. Thus, a double hook safety device is effectuated by the embodiment of the safety device shown in FIGS. 11-15.

FIG. 14 is a plan view of housing 4, which is shown to have been pivoted away from base 2. In this view, both hooks 40 and 42 are clearly shown. The same is true with respect to the side view of the safety device shown in FIG. 15, where rib 44, and its opening 46, are clearly shown. The enlarged detail of the latch rib is shown in FIG. 16. The cross-sectional view A-A of the FIG. 13 safety device is shown in FIG. 18. As was noted previously, the fully actuated safety device whereby the catch mechanisms at the housing and base are fully interlocked is shown in FIG. 19.

Another embodiment of the present invention is shown in FIGS. 20-22. Elements for this embodiment that are same as the earlier embodiments are labeled the same.

In particular, the needle assembly of FIG. 20 is shown to have been matingly connected to a syringe 50. Similar to the earlier embodiments, the safety device or needle assembly of FIG. 20 has a housing 4 hingedly connected to a base 2. As shown in FIGS. 21 and 22, base 2 has a proximal end 14 and a distal end 10. At the distal portion of the needle assembly there are a number of ribs or extensions 50 a-50 d that extend from base 2. At rib 50 a, which extends orthogonally from the longitudinal axis of base 2 (as defined by needle 8) to face housing 4 as housing 4 is pivoted towards base 2, there are provided at the planar sides of rib 50 a two fingers or bosses 52 a and 52 b. As best shown in FIG. 22, bosses 52 each are configured to have a finger portion for grasping and fixedly retaining a corresponding loop or ring 54 a and 54 b that extend from the back wall 24 of housing 4, when housing 4 is pivoted to cover needle 8. For the embodiment of FIGS. 20-22, the loops 54 a and 54 b may be considered as one catch mechanism or catches while bosses 52 a and 52 may be considered as another catch mechanism or catches. As shown in FIGS. 21 and 22, loops 54 a and 54 b extend from back wall 24 of housing 4 in an adjacent fashion leaving a space 56 therebetween. Space 56 is configured to be of a given width so that, as loops 54 a and 54 b coactingly mate with bosses 52 a and 52 b, respectively, rib 50 a is sandwiched by loops 54 a and 54 b.

In addition to providing rigidity, the multiple ribs 50 are configured to allow the open end of a needle protection sheath 60 that covers needle 8 prior to use to be frictionally fitted thereabout.

Further provided as part of housing 4 in the embodiment of FIGS. 20-22 are a pair of partition walls, or simply partitions 58, that also extend from back wall 24 of housing 4. Each of partitions 58 is interposed between one of the loops 54 and one of the sidewalls 22 of housing 4. As shown in FIG. 22, once the loops 54 snap over and are secured to the respective bosses 52 and needle 8 is covered by housing 4, the front edge of each of the partitions 58 would either come into contact with, or be in very close proximity to, respective ribs 50 b and 50 d, so that the engaged or interlocked bosses/loops are prevented from being accessed, and possibly tampered with. This is a safety measure that is in addition to the previously discussed segments 58 of the sidewalls of the housing being used to preclude someone from accessing the catch mechanisms, after the catch mechanisms have been mated to securely retain housing 4 and base 2 relative to each other.

As with the other embodiments, a mechanism such as a hook 40 is integrated in housing 4 for grasping needle 8, when housing 4 is pivoted towards base 2 to cover needle 8. Hook 40 and the respective boss and loop catch mechanisms are designed such that hook 40 would come into contact with and grasp needle 8 at substantially the same time that loops 54 snap over and are secured to bosses 52.

As with the other embodiments previously disclosed, the needle assembly of FIGS. 20 to 22 may be made as an integral unit and may be color coded to different predetermined colors for signifying the different gauges of needles that may extend from the needle assembly. 

1-13. (canceled)
 14. A method of preventing exposure of a needle after use for a safety device adaptable to mate with a syringe at its proximal end and having fitted to its distal end the needle, said safety device including a housing and a base pivotally connected to each other, said housing having a back wall and two sidewalls together forming a slot through which the needle passes when said housing is pivoted toward said base to cover the needle, the method comprising the steps of: a) extending one catch mechanism from said back wall; and b) providing an other catch mechanism at said base at a location that ensures said one and other catch mechanisms are non-removably interlocked to each other when said housing is pivoted to cover the needle.
 15. Method of claim 14, further comprising the steps of: extending a rib from said base in the direction facing said housing when said housing is pivoted towards said base; and providing said other catch mechanism at said rib.
 16. Method of claim 15, wherein said one catch mechanism comprises a pair of adjacent loops and wherein said other catch mechanism comprises a pair of bosses, the method further comprising the steps of: providing a boss at each side of said rib; and extending said pair of loops from said back wall; wherein when said housing is pivoted to cover the needle, each of said loops snaps over a corresponding one of said bosses and be interlocked therewith, said rib being sandwiched by said loops after said respective loops are interlocked to said bosses.
 17. Method of claim 14, further comprising the step of: providing a proximal extension to each of said sidewalls to prevent access to said catch mechanisms once said catch mechanisms interlock to couple said housing and said base to each other.
 18. Method of claim 14, further comprising the steps of: extending a pair of partitions from said back wall of said housing; positioning said partitions between the sidewalls of said housing so that said one and other catch mechanisms are sandwiched by said pair of partitions when said housing pivots to cover the needle.
 19. Method of claim 14, further comprising the steps of; molding said housing and said base as a single unit; and color coding said housing and said base a predetermined color that signifies the gauge of the needle.
 20. Method of claim 14, further comprising the step of: extending a hook from said back wall for non-removably clasping said needle when said housing is moved to cover said needle, said hook clasping said needle at substantially the same time that said one and other catch mechanisms are interlocked to each other.
 21. A method of manufacturing a needle assembly, comprising the steps of: a) forming a base having a needle extending therefrom along a longitudinal axis thereof and a housing having two sidewalls connected by a back wall pivotally connected thereto; b) form a first catch mechanism that extends from the back wall of said housing; and c) forming a second mechanism at a rib that extends from said base, said rib facing the back wall of said housing when said housing is pivoted toward said base; wherein said first and second catch mechanisms fixedly retain to each other when said housing is pivoted to said base to cover the needle.
 22. Method of clam 21, wherein said step a further comprises the step of extending a pair of adjacent first catches separated by a space from the back wall of said housing; and wherein said step c further comprises the step of forming a pair of second catches at said rib; wherein each of said first catches mates with a corresponding one of said second catches to fixedly retain said housing and said base relative to each other when said housing is pivoted to said base to cover the needle.
 23. Method of claim 22, further comprising the step of providing a given width for the space separating said first catches to ensure that said rib is sandwiched by said first catches when said first and second catches are respectively mated to each other.
 24. Method of claim 21, wherein said step b further comprises forming said first catch mechanism as one pair of loops separated by a space that extend from the back wall of said housing; and wherein said step c comprises forming said second catch mechanism as a pair of bosses at said rib; wherein each of said loops snaps over and secure to a corresponding one of said bosses when said housing pivots toward and covers said needle.
 25. Method of claim 21, further comprising the step of: color coding said base and said housing to have a predetermined color that signifies the gauge of the needle of the needle assembly.
 26. Method of claim 21, further comprising the step of: extending a pair of partitions from said back wall of said housing to sandwich said first catch mechanism, said pair of partitions preventing access to said first and second catch mechanisms once said first and second catch mechanisms are fixedly attached to each other.
 27. Method of claim 26, wherein said first catch mechanism comprises a pair of spaced first catches and said second catch mechanism comprises a pair of second catches at said rib; further comprising the step of: interposing each partition between one of the sidewalls and a corresponding one of said first catches so that said first catches are sandwiched by said partitions which in turn are sandwiched by said side walls.
 28. Method of claim 21, wherein said step b further comprises the step of forming said first catch mechanism as a pair of fingers; and wherein said step c comprises the step of forming said second catch mechanism as an anchor; wherein said anchor is grasped by said fingers to fixedly retain said housing and said base to each other when said housing is pivoted to said base to cover the needle.
 29. Method of claim 21, wherein said step b further comprises the step of forming said first catch mechanism as a hook; and wherein said step c comprises the step of forming said second catch mechanism as a latch; wherein said hook interlocks to said latch to fixedly retain said housing and said base to each other when said housing is pivoted to said base to cover the needle. 